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1. BLEND amp RECLAIM GH M Rate Monitor Siemens S7 200 Controller Part Number 882 00724 00 Bulletin Number BF2 600 Effective 02 08 2007 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2008 All rights reserved il Shipping Info Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Ad
2. 7 Finally the controller will ask you to remove the calibration weight and press OK to complete the calibration 8 The controller will verify that the calibration was done correctly by showing Calibration Successful 9 Press Done until you have reached the Recipe screen Figure 16 Display Calibration Screen Enter in the Calibration Weight Bits Calibration Weight for Meu Press here to perform the calibration Follow Instructions Go Back to the Calibration Directory Verifying Calibration Recommended on a periodic basis to ensure accuracy Current Loadcell Calibration Load Cell Bits 4HHHHHHt ENTER CALIBRATION WEIGHT ABOU i E then Remove Weigh Hopper and press OK 1 From the Recipe Page touch the Manufacturer s icon and enter 5413 then press the Enter key 2 Touch Calibration and then Direct Scale Readout Ensure the weigh hopper is empty 4 Locate the weight display for the load cell directly below Current Bits Write down the displayed value Bulletin Number Chapter 3 Installation 30 of 61 Add the calibration weight to the weigh hopper and write down the value displayed in weight as in step 4 Subtract the values recorded in step 4 from step 5 This is the measured weight If the measured weight is within a 0 003 pounds of the weight stamped on the calibration weight then you are within spec If not follow the
3. Below are the items that can be accessed for the hopper 7 4 ITEMS IN BLUE ARE READ ONLY ITEMS IN BLACK ARE WRITE ONLY Bulletin Number Chapter 7 Appendix 53 of 61 Chapter 8 Bulletin Number Chapter 8 54 of 61 Chapter 9 Item GENERAL HOPPER INFO 1 hopper weight percent O23 0 1150 easy to use scale to show weight 2 total weight minus tare O F 24 this is the material weight 3 reload output O1 BIT 4 to show reloading HOPPER MODE STATUS 1 ramp to stop engaged Ol BIT 0 2 monitor mode engaged O1 BIT 1 3 control by rpm engaged O1 BIT 2 4 control by weight engaged O1 BIT 3 5 alarm active O32 BITO 6 system heart beat O32 BIT 1 HOPPER MODE CONTROL 1 ramp to stop pushed Il BIT 0 toggle this bit to stop line 2 monitor mode pushed I1 BIT 1 toggle this bit to put in monitor mode 3 control by rpm mode pushed I1 BIT 2 toggle this bit to put unit in rpm mode 4 control by weight mode pushed I1 BIT 3 toggle this bit to put unit in weight mode HOPPER ALARMS 1 hopper low level alarm O2 BIT 0 2 hopper out of material alarm O2 BIT 1 3 hopper over filling alarm O2 BIT 2 4 extruder no rpm detected alarm O2 BIT 4 5 extruder no flow detected alarm O2 BIT 5 6 hauloff drive failure alarm O2 BIT 6 7 loadcell over max alarm O2 BIT 7 8 reload too long alarm O2 BIT 8 9 alarm active O32 BITO INVENTORY INFO 1 clear inventory I1 BIT 4 toggle this to clear all invent
4. ACS i cx Group EXT WTF Stable To access the Setup Menu to change the controller features refer to the following pages of this manual Controller Set up This section describes the proper setup of the rate monitoring system control parameters These parameters are operator changeable however these items should only require setup Bulletin Number Chapter 3 Installation 26 of 61 during the initial installation Only authorized personnel should change them For security reasons the menu that is used to access these parameters is password protected Many of the variables and setup parameters have been preset at the factory and do not need to be changed However this section of the manual will address all of the rate monitor setup parameters that were available at the time of printing The purpose of this is to familiarize the reader with all the setup parameters and their usage A complete listing of all default values is provided at the end of this manual Bulletin Number Chapter 3 Installation 27 of 61 Recipe Page Start Extruder RPM is displayed Extruder throughput is displayed Access Inventory Page Access Setup Page Next to access Inventory page Bulletin Number GH Controller Menu Structure Inventory page gt Clear Inventory gt Manual Control gt Next returns to Recipe page Manual Control Page gt Reload ON OFF gt Return to the Inventory Page Setu
5. Hauloff Encoder Calibration Distance Per revolution of Encoder 000 00 ft Measured Hauloff Speed 0000 0 ft min SCALE CHLIBEBTID Calibration Weight Lbs To automatically calculate Distance C JL Si Bn HHHHHHH Per Revolution enter actual measured speed below then dick here Load Cell Bits 48 n TIER CALIBRATION WEIGHT DUE then Remove Weigh Hopper and press OK Bulletin Number Chapter 2 Functional Description 19 of 61 Vacuum Bypass Setup Enter the weight DIRECT SCALE READOUT Cal Weight used that is held above in stored HEHEHE Lbs the reload gate calibration Load el Be sure to consider Zero Bits Weight the weight in the Cal Bits dHHHHHHE IHHHHHHE vacuum hopper Current Bits HH Weight HHH 44 Lbs Total Weight HHH 44 Lbs Total wt minus tare wt Lbs LAR TT SE TUE Min System Speeds May System Speeds Hopper X for low level alarm Panel lieu GH Version Main 1 5 F PLC GH Version SHHH Hopper X for no material alarm PLC Operating System Series S Gut of Material PLC Operating System Firmware dE Alarm Silence Delay Select Operator mung NEW PASSWORD VERIFY PASSWORD 2 4 Optional Components The following is a list of options which your rate monitor may have been equipped with Profibus DP Slave In lieu of an inductive proximity switch the extruder s RPM may be written through communications To accomplish this y
6. In the case of a metric display the weight to be used is calibrated in kilograms Given the two weight points on the load cell scale the controller should determine any other weight on the load cell span This is limited to the maximum capacity of the load cell The standard load cell used on rate monitors has a span accuracy of 10 The maximum capacity of each load cell is clearly marked on top of the load cell This value will be indicated in kilograms 1 kg 2 2 Ibs Note It is not necessary to calibrate the weight scale on a brand new rate monitor although it is recommended that the calibration be checked periodically to ensure that the reported inventory totals are accurate Weigh Hopper Load Cell Calibration 1 From the Recipe Page touch the Manufacturer s icon and enter 5413 then press the Enter key 2 Touch Calibration and then Scale Calibration Bulletin Number Chapter 3 Installation 29 of 61 Figure 15 Display Calibration Menu Screen Go Back to Setup Directory Scale Calibration irect Scale Readou Feeder Calibration 3 Oncein Scale Calibration enter in the scale calibration weight value stamped on the side of the weight 4 The controller will prompt you to empty the weigh hopper and press OK After touching OK the controller will display PLEASE WAIT 6 Next the controller will ask you to hang the calibration weight on the weight hopper and press OK
7. Note Allow at least 36 clearance around the rate monitor to provide adequate room for cleaning servicing etc Using proper lifting equipment lift the rate monitor Affix the rate monitor to the processing machine Note Larger rate monitors may need to be braced as part of the installation Take care to insure proper orientation with adequate access to operator controls mix chamber and metering units Note Never weld on the rate monitor support stand machine or mezzanine without first removing the control panel and verifying that the rate monitor is properly grounded 3 3 Electrical Connections The standard rate monitor system is designed to operate on 120 1 60 or 220 1 60 supply voltage For exact current requirements check the GH Hopper serial number tag located on the right side of the PLC enclosure If a step down transformer was provided it should never be used to power anything other than the rate monitor Loading equipment etc must be powered by another power source As well as possibly overloading the transformer the additional equipment may induce power line noise that may affect the operation of the rate monitor The transformer will be mounted and wired by the customer or your installer If company or local codes require fusing or disconnects these items must be supplied wired and mounted by the customer Note Each rate monitor MUST be connected to a separate source of power Do not connect other electrical
8. first reading and understanding this manual e NEVER try to pull material out of the rate monitor with your hands while it is running Before you start the GH Hopper check the following e Remove all tools from the unit Be sure no objects tools nuts bolts clamps bars are laying in the feeding area Note Note Note Note If your rate monitor has been inoperative or unattended check all settings before starting the unit At the beginning of your shift and after breaks verify that the controls and other auxiliary equipment are functioning properly Keep all safety guards in place and in good repair NEVER attempt to bypass modify or remove safety guards Such alteration is not only unsafe but will void the warranty on your equipment When changing control settings to perform a different mode of operation be sure selector switches are correctly positioned Locking selector switches should only be adjusted by authorized personnel and the keys removed after setting Report the following occurrences IMMEDIATELY e Unsafe operation or condition e Unusual action e Leakage e Improper maintenance Note Note Note Note Bulletin Number NEVER stand or sit where you could slip or stumble into the rate monitor while working on it DO NOT wear loose clothing or jewelry which can be caught while working on a rate monitor In addition cover or tie back long hair Clean the rate monit
9. Continuous 1 Intermittent 2 Nominal supply voltage 120 1 60 or 220 1 50 60 Verify on serial number tag Earth ground type TN system has one point directly earthed through a protective conductor Power supply should include a neutral power connection Over current protection is supplied in the GH Hopper but additional protection should be supplied by the user The plug on the power cord serves as the electrical disconnect device Unit is not equipped with three phase motors Functional identification No one is required to be in the interior of the electrical enclosure during the normal operation of the unit Only skilled electricians should be inside the enclosure for maintenance Doors can be opened with a screwdriver but no keys are required All hoppers should be moved around and set in a place with a lift truck or equivalent There are no frequent repetitive cycles that require manual control repetitive functions are automatic while the GH Hopper is operating An inspection report detailing the functional test is included with the GH Hopper The machine is not equipped with cableless controls Color coded harmonized power cord is sufficient for proper installation Chapter 7 Appendix 45 of 61 Figure 57 Typical Surge Hopper Assembly Parts List DESCRIPTION 010 020 040 Lid Smaller
10. S7 200 CPU 226 PLC e Thermocouple Input card for loadcell e Manual key switch control function for reload e Visual Alarm e Full control diagnostics e Profibus DP Slave Module System Component Description This section describes the various components of the rate monitor system Bulletin Number Chapter 2 Functional Description 14 of 61 Extruder Inductive Proximity Switch The extruders RPM must be reported to the GH M controller for the system to function To accomplish this an inductive proximity switch is provided to let the GH M controller know the RPM of the extruder This switch should be field mounted in an appropriate way to read the extruder s true RPM It is important this switch is reading the actual RPM of the Extruder and not an RPM before a gearbox for example Chapter 3 will detail the installation and wiring of this component Because it is field mounted wiring of the proximity switch will NOT be done at the factory and we do not provide any custom mounting brackets for your application as these vary depending on the equipment This measurement can also be achieved by writing the extruder s rpm through communications see document at the end of this manual for details If this is done through communications then it eliminates the need to install the extruder proximity switch Surge Hopper The surge hopper is located on top of the GH M frame These hoppers store a supply of material to fill the weigh hopper The surg
11. You are now ready to run the unit as normal The Steady flag indicates that the measured throughput in reliable and can be used for control The system will automatically stop loading the hopper upon stopping the extruder There is no need to manually start stop a GH M unit Bulletin Number Chapter 3 Installation 35 of 61 Chapter 4 Operation 4 1 Start up General Operation 1 Aslong as the steady flag is present the system will run and monitor your process rate without interaction giving you a continuous real time measurement 2 If the extruder is stopped then the GH system will stop automatically Quick Start Procedure Generic 1 Calibrate the weigh hopper before running the system This will improve inventory and measured throughput accuracy 2 Ensure the surge hopper has adequate material to fill the weigh hopper 3 Verify the extruder s RPM is being supplied to the controller 4 Wait for the Steady Process indicator to appear and then use the measured extruder throughput for control 4 2 Operation Procedures Operator Displays Figure 33 Typical Operator Screen ACSBB i cx Group EXT HTP Stable Bulletin Number Chapter 4 Operation 36 of 61 Figure 34 Typical Manual Control Operator Screen MAHJAL CONTROL CAUTION iram Will stop if manual reload is turned on Hop Hr Hoey Lbs While the rate monitor system is in operation there are a couple of display
12. and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material the manufacturer must give authorization A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms iv Table of Contents CHAPTER 1 SEENEN 14 Howto Use This Manual nt eene e e eoe repo Rad Fen ir EE dee 7 Safety Symbols Used in this Manual seen 7 1 2 Warnings and Pre eau lonis dede de ette iei ete Cady casi de bares Dui o emm eei dix espe dag ees 9 E Ee ele EE 10 General Responsibility EE 10 Operator Responsibility E 10 Maintenance 709 20775 0 1 EE 12 Reporting a E 12 CHAPTER 2 FUNCTIONAL DESCRIPTION 13 2 1 Models Covered in This Manual oett rte tek ee eb Rue xn 13 2 2 General BI To TEE 13 AUCOSSOIBGS eoe tics desse am ML t DR EM DE D 13 CUSIOIDBI SOIVICO ee ege 13 2 3 Typ
13. checklist below contains a list of items which should be inspected and or replaced to keep your GH Hopper operating at peak efficiency Perform each inspection at the regular intervals listed below Figure 52 Sample Preventative Maintenance Schedule Dail Date Date Date Date Date Date Date Date Date Date Date Date Date y By By By By By By By By By By By By By Inspect hopper for any loose parts tighten them immediately Verify quality of compressed air supply Inspect weigh hopper for obstructions Date Date Date Date Date Date Date Date Date Date Date Date Date Every week TES Verify the rate monitor is properly calibrated Check to make sure that all hose connections are air tight Inspect air regulator and air safety circuits if equipped Recalibrate rate monitor If necessary Photocopy this page for your maintenance records Bulletin Number Chapter 5 Maintenance 39 of 61 5 2 Preventative Maintenance Our GH Hoppers need periodic maintenance to provide long dependable service Check these elements regularly e Check functionality of safety circuit daily e Maintain proper air pressure and drain water from trap assembly on regulator as required WARNING Always remove plug and disconnect power before servicing hopper EC WARNING Always read operating manual before operating or servicing hopper 5 3 Cor
14. circuit You might have a bad loadcell Other service problems or questions can be answered by contacting the Service Department Bulletin Number Chapter 6 Troubleshooting 43 of 61 Chapter 7 Appendix 7 1 Warranty and Spare Parts Unless otherwise specified this product includes a Standard ONE YEAR PARTS WARRANTY Warranty Specifications The manufacturer hereby expressly warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions as set forth in the operating manuals for such equipment THE FOREGOING EXPRESS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES GUARANTEES AGREEMENTS AND SIMILAR OBLIGATIONS OF THE COMPANY AND OR MANUFACTURER UNLESS OTHERWISE SPECIFIED IN THE SPECIFIC PRICE PAGE OR LIMITED BY THE MANUFACTURERS WARRANTY FOR PARTS The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty Warranty Restrictions This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits inclu
15. controller Abort Stops GH Hopper amp restarts controller Press to move back one screen level in controller function Move forward one screen level in controller function EERE Hent Bulletin Number Chapter 2 Functional Description 17 of 61 Figure 10 Typical Operator Screens ACS EXT RPM Stable Group EXT WTP Stable version Main 1 5 Extrusion Monitoring a gt PLO Wersion Copyright HHH A 2004 ACS Total Lbs W nn 8 CAUTION E stem Will stop if manual Grou Total Feet HHHHHHHEHE cadis earned E Hop Ht iHa Lbs Clear Manual Inventory Control dE Operator eee ace has been locked Bulletin Number Chapter 2 Functional Description 18 of 61 Figure 11 Typical Setup Screens Recipe Format Manual Control Hopper Setup Hauloff is not enabled Extruder Setup System Rate Weight Per Weight Per amp Line Speed Length Mode Area Mode Hauloff Setup Calibration Panel Config Grams per feet i 58 reng Maintain Layfiat in p Passwords Extruder RPM meters Hopper size dHHHHHBHE Lbs Reload Percentage o 4 HAULOFF SETUP x 00000 0225 Hauloff Max Speed 0000 0 Target Hauloff Speed 0000 0 ft min Measured Hauloff Speed 0000 0 ft min Maximum Extruder RPM HHH UML FUR H GAR FEEDER GHF Extruder Mas Throughput lbs hr Calibrate Encoder RPM or Weight Mode only
16. equipment especially self contained hopper loaders on the same line as the rate monitor Ensure that the power entrance location on the rate monitor panel remains unchanged Make sure that the proper size wire and proper wire routing techniques are used when installing the Bulletin Number Chapter 3 Installation 23 of 61 supply wiring to the control panel Care must be taken to ensure that the supply wiring does not interfere with the low voltage DC wiring The rate monitor is supplied with a plug that functions as the disconnect device The mating receptacle must be installed no higher than 5 feet 1 6 m above the floor Make sure your installation conforms to your regional electrical standards Please refer to the supplied electrical schematics for detailed connection points for the supply power 3 4 Pneumatic Connections The rate monitoring system uses plant supplied compressed air to operate the surge hopper CLEAN AND DRY air must be supplied to the rate monitor The air supply should be filtered through a 5 micron air filter with a water separator Oil should not be used unless air dryers are installed on the compressed air supply In this situation an oiler may be required on the rate monitor to keep the air cylinder seals lubricated Usage is about 5 cu inches per refill A single 1 8 NPT standard pipe thread fitting is provide on the surge hopper solenoid to supply air pressure Caution To prevent damage to
17. ft and the second entry is set to extruder rpm input then the target Ibs ft and the extruder rpm is set by the operator while the PLC calculates the target feet min needed to achieve the desired recipe No set points can be modified while in Monitor Mode The PLC will take constant snap shots of the extruder RPM haul off speed and recipe set points and will write these to ensure a bump less transfer when entering into either RPM Mode or Weight Mode The system can be placed in RPM Mode or Monitor Mode from stop at any time The system can go from RPM Mode Weight Mode or Monitor Mode into stop mode at any time as well However there are restrictions when transferring between other modes The system must be stable before it will allow you to transfer from RPM Mode into Weight Mode Also the system must be stable when transferring from Monitor Mode to RPM Mode If you are in Monitor Mode you must transfer into RPM Mode and then stabilize before going into Weight Mode SHUTDOWN SEQUENCE EXPLANATION The hopper has the ability to shutdown the loading system prior to the line shutting off to eliminate material in the supply hopper If you write any non zero value to desired shutdown time in minutes then the GH will calculate based on the current process rate recipe and preset at the touch screen supply weight amount of material that the supply hopper will store when it should disab
18. help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the GH Hopper These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the GH Hopper safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your GH hopper provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or seriou
19. machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Figure 53 Typical Troubleshooting Problems and Suggested Corrective Actions Problem Corrective action Check to make sure that air is hooked up and the regulator gauge reads at precisely 60 PSI Nothing happens when I start the extruder Look on the Recipe Screen If you don t see a displayed Extruder RPM then check the inductive proximity switch If you do see a displayed RPM then check the hopper s calibration Interface has been Locked is shown Tve toreonen ny Uer Contact the Service Department Password Change out the PLC with your spare and reprogram new unit PEC Banery Low Send old PLC back to Manufacturer for repair Click Unlock and enter in your
20. promptly upon request Note If you desire to use a rate monitor for an application other than that for which it was purchased please contact your sales representative or our factory to verify compatibility of the equipment with the new process Misapplication of the equipment could result in injury to the operator or damage to the equipment Bulletin Number Chapter 2 Functional Description 13 of 61 Figure 2 Equipment Specifications Mode 10 20 40 Maximum Extrusion Rate Ibs hr kg hr 600 272 1200 680 2500 1134 Weigh Hopper Capacity cu ft Liters 0 35 10 0 7 20 1 41 40 Typical Weigh Hopper Size 166 Load Cell Capacity kgs 1 100 1 20kg 1 30 kg Approximate Dimensions in mm Height 5 34 5 875 51 5 1308 56 5 1435 Width 5 26 0 650 37 5 952 37 0 940 Depth 5 22 0 560 37 0 940 40 0 1016 2 3 Typical Features and Components Mechanical Features e Removable stainless steel weigh hoppers e Stainless steel surge supper supply hopper with integral air cylinder and urethane dump cone e Precision 1 10 span accurate cantilever load cell weighing system e Inductive extruder tracking proximity switch Rugged industrial mild steel painted frame Cast aluminum spool with drain and purge ports Figure 4 Typical GH Siemens S7 200 PLC Enclosure Controller Features e LCD touch screen interface display operator control panel with 8 cable e Siemens
21. this group the safety program can be continually reviewed maintained and improved Keep minutes or a record of the meetings Hold daily equipment inspections in addition to regular maintenance checks You will keep your equipment safe for production and exhibit your commitment to safety Please read and use this manual as a guide to equipment safety This manual contains safety warnings throughout specific to each function and point of operation Operator Responsibility The operator s responsibility does not end with efficient production The operator usually has the most daily contact with the equipment and intimately knows its capabilities and limitations Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates or through a casual attitude toward machinery formed over a period of months or years Your employer probably has established a set of safety rules in your workplace Those rules this manual or any other safety information will not keep you from being injured while operating your equipment Bulletin Number Chapter 1 Safety 10 of 61 Learn and always use safe operation Cooperate with co workers to promote safe practices Immediately report any potentially dangerous situation to your supervisor or appropriate person REMEMBER e NEVER place your hands or any part of your body in any dangerous location e NEVER operate service or adjust the rate monitor without appropriate training and
22. vacuum receivers 08223 1 872 00769 00 872 00830 00 1 Lid Larger vacuum receivers NA 872 00783 00 Lid Tube Stub for Mezz Mounted GH Hopper 08223 2 2 1 8 NPT fitting 35085K 35086K 3 1 4 NPT fitting 35154 35155 4 Bulkhead 35146 5 Brass elbow 35118 6 24V DC Solenoid 33128 7 Dump cone 15370 15237 8 Aircylinder 33126 33073 33011G Figure 60 Typical Weigh Hopper Assembly Parts List DESCRIPTION 010 020 040 1 WEIGH HOPPER 822 00382 00 822 00383 00 822 00384 00 2 LOAD CELL 61 1010E 10KG A0564528 A0564546 LOAD CELL 3 BRACKET 872 00669 00 Figure 64 Typical Siemens S7 200 Controller Main Parts List Description ALL MODELS 1 Siemens 87 200 CPU 226 744 00157 00 2 Siemens EM277 Profibus DP Slave 744 00170 00 3 Siemens TC EM 231 Analog Module 744 00191 00 4 24V DC Power Supply A0563932 5 12V DC Power Supply 739 00027 00 6 Alarm Light Yellow Strobe 24V DC A0565889 7 Glass Fuse 3 0 amp 115v unit A0542207 10 120V Light power switch 715 01034 02 Figure 65 Typical Siemens 87 200 Display Main Parts List Description All MODELS 1 Complete Display Panel TP177 with Bopla Box 892 01327 00 2 Siemens TP177 Micro Touch Screen 744 00159 00 3 Display 8 ft Connection Cable A0565856 Display 50 ft Connection Cable A0565899 Bulletin Number Chapter 7 Appendix 46 of 61 7 2 Addendum Service Supervisor Information Note Untrained personnel of the rate monitor controller shou
23. when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor General Responsibility No matter whom you are safety is important Owners operators and maintenance personnel must realize that every day safety is a vital part of their jobs If your main concern is loss of productivity remember that production is always affected in a negative way following an accident The following are some of the ways that accidents can affect your production e Loss of a skilled operator temporarily or permanently e Breakdown of shop morale Costly damage to equipment e Downtime An effective safety program is responsible and economically sound Organize a safety committee or group and hold regular meetings Promote this group from the management level Through
24. 2 V1414 V1416 Bulletin Number PLC BYTE V1365 0 V1365 1 V1365 2 V1365 3 V1365 4 V1365 5 V1365 6 V1365 7 V1364 0 V1367 0 V1367 1 V1367 2 V1367 3 V1367 4 V1367 5 V1367 6 V1367 7 V1366 0 1 ADDRESS WORD TYPE INT INT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT FLOAT INT FLOAT GH OUTPUT BLOCK READ HERE DESCRIPTION bit O ramp to stop engaged bit 12 monitor mode engaged bit 2 control by rom mode engaged bit 3 control by weight mode engaged bit 4 reload output on bit 5 system stable flag bit 6 extruder rpm stable flag bit 7 extruder throughput stable flag bit 8 hauloff stable flag bit O hopper low level alarm bit 1 hopper out of material alarm bit 2 hopper over filling alarm bit 3 not used bit 4 no extruder rpm detected alarm bit 5 no extruder flow detected alarm bit 6 hauloff drive failure alarm bit 7 loadcell over max alarm bit 8 reload too long alarm hopper inventory MSW hopper inventory LSW hauloff accumalated length MSW hauloff accumalated length LSW extruder RPM target MSW extruder RPM target LSW actual extruder RPM instant MSW actual extruder RPM instant LSW hauloff speed target MSW hauloff speed target LSW current measured hauloff soeed MSW current measured hauloff speed LSW recipe running target MSW recipe running target LSW recipe actual value MSW recipe actual value LSW extruder WTP Target MSW extruder WTP Target LSW ext
25. Appendix 52 of 61 7 3 Siemens S7 200 Communications Manual The Siemens GH Hopper uses a S7 200 CPU 226 processor communicating acting as a DP Slave using a EM277 Siemens Profibus module The node address is configured via 2 dials on the front of the module that is located in the PLC rack The GSD file requires the user to specify where in memory the top of the input data block is located area where the master will write to us This address if V1300 and should be added to the GSD file before being downloaded EXPLANATION OF INPUT ANNOTATION I 16BIT UNSIGNED INTEGER I D 32BIT UNSIGNED INTEGER I F 32BIT IEEE FLOAT LBIT X SINGLE BIT VALUE EXPLANATION OF OUTPUT ANNOTATION O 16BIT UNSIGNED INTEGER O D 32BIT UNSIGNED INTEGER O F 32BIT IEEE FLOAT O BIT X SINGLE BIT VALUE The Profibus interface module has 32 words 1 32 in the input block and 32 words 1 32 in the output block Starting at word 1 ALL BIT REFERENCES IN THIS MANUAL REFER TO THE BIT ORDER OF A 16 BIT SIEMENS WORD SIEMENS USES BIG ENDIAN LITTLE ENDIAN PRINCIPLES AND THEREFORE THE FIRST BYTE IS ACTUALLY THE MOST SIGNIFICANT BYTE BIT 0 OF THE FIRST WORD REFERS TO THE LEAST SIGNIFICANT BIT THIS BIT IS STORED AT THE START OF THE SECOND BYTE OF THE WORD IF VW1300 WAS THE 16 BIT WORD BEING ADDRESSED THEN BIT 0 OF THIS WORD WOULD ACTUALY BE V1301 0 AND NOT V1300 0 SINCE ALL PROFIBUS DATA IS IN WORDS WE REFER TO THIS STANDARD FORMAT THROUGHOUT THE MANUAL
26. H WTP RPM Filter Steady WHTPZRPM Window Max Allowed WTPZRPM pone WTP Algorithm Options Screen Bulletin Number Chapter 7 Appendix 48 of 61 The method that is used to calculate the measured lbs hr is entirely adjustable to fit any application The three methods that can be used is Extruder Pulse Count Method Percent of Hopper Method or Full hopper Method You cannot use the Extruder Pulse Count Method if you are writing the extruder speed through communications instead of using our inductive proximity switch Extruder Pulse Count Method This method updates the weight every Number of Pulses for Calculation detected by the extruder proximity switch This is not the most automated method of the 3 choices but has it s advantages If you are using an unusually large extruder and running it in production at a very low speed then this method works best because the snapshot is taken at the same rotational position of the extruder and eliminates errors in measurement that are caused by the pulsing of the feed throat Percent of hopper Method DEFAULT This is the most automated and responsive of the 3 choices The snapshot sample is based on the Percent of Hopper for Calculation setting The smaller you make this setting the quicker the hopper will update If this value is set too small then you will be measuring the instantaneous throughput of the feed throat instead of the average loss in weight The av
27. S Keep fingers away from slide gates augers clean outs and calibration hatches Automatic operation may start unexpectedly A PINCH HAZARD CAPABLE OF CAUSING BODILY INJURY EXISTS ANY TIME THE POWER IS ON Wear SAFETY GLASSES and WORK GLOVES Work only with approved tools and devices Disconnect and or lock out power and compressed air before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you NEVER PUT FINGERS OR TOOLS IN AN AUGER OR SLIDE GATE AREA Make sure the equipment and components are properly GROUNDED before you switch on power Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality Bulletin Number Chapter 1 Safety 9 of 61 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and
28. SS V1300 V1302 V1304 V1306 V1308 V1310 V1312 V1314 V1316 V1318 V1320 V1322 V1324 V1326 V1328 V1330 V1332 V1334 V1336 V1338 V1340 V1342 V1344 V1346 V1348 V1350 V1352 V1354 V1356 V1358 V1360 V1362 Bulletin Number PLC BYTE ADDRESS WORD TYPE V1301 0 V1301 1 V1301 2 V1301 3 V1301 4 V1301 5 V1301 6 V1301 7 V1300 0 1 INT FLOAT FLOAT FLOAT FLOAT 10 FLOAT 12 INT GH INPUT BLOCK WRITE HERE DESCRIPTION bit O ramp to stop pushed bit 12 monitor mode pushed bit 2 rom mode pushed bit 32 control by weight mode pushed bit 4 clear inventory bit 52 change entered extruder RPM target bit 62 change entered hauloff speed bit 7 change entered recipe target bit 8 change layflat entered extruder RPM target MSW entered extruder RPM target LSW extruder RPM instant MSW extruder RPM instant LSW entered hauloff speed MSW entered hauloff speed LSW entered recipe target MSW entered recipe target LSW layflat MSW layflat LSW desired shutdown time in minutes not used not used not used not used not used not used not used not used not used not used not used not used not used not used not used not used not used not used not used not used Chapter 9 Item 58 of 61 PLC WORD ADDRESS V1364 V1366 V1368 V1370 V1372 V1374 V1376 V1378 V1380 V1382 V1384 V1386 V1388 V1390 V1392 V1394 V1396 V1398 V1400 V1402 V1404 V1406 V1408 V1410 V141
29. User Password Bulletin Number Chapter 6 Troubleshooting 42 of 61 PLC Module Loaded Weigh hopper occasionally overfills Problem Normal after a software upgrade Follow on screen instructions Lower the hopper size under Hopper Setup Corrective action Recorded Inventory Totals don t match what I ve actually used Printer did not print Problem The feeder calibration values are moving too much Problem Check the hopper s scale calibration and verify that the hopper is not overfilling If the hopper is overfilling adjust your hopper size If this 16 correct then you are probably not accounting for material scrap or other items in your process Check that the printer is a SERIAL printer If not then you will need to either get a SERIAL printer or purchase a SERIAL to PARALLEL converter Corrective action Check to ensure that the weigh hopper is not touching any part of the frame and that the loadcell bracket is not touching the plastic cover of the loadcell If these have been verified then check loadcell and replace if necessary Corrective action I can t calibrate the Scale without an error message Note This Is caused by the difference in bits not being large enough Using the Direct Scale Readout examine current loadcell bits with and without the calibration weight If the bits do not change significantly then check for pellets jamming the loadcells and check the loadcell
30. acity Caution Use approved safety straps or chains to lift the rate monitor 3 Liftthe rate monitor until strap is taut 4 Remove bolts attaching bottom of the rate monitor to shipping skid Mechanical Installation It is the intent of this section to familiarize the reader with the proper site requirements and installation procedures of the GH M rate monitoring system The information in this section is NOT meant to replace or supersede an established local or company implemented procedures It is meant to enhance them The installation procedure should be used as a general guideline for the proper installation steps required to install a rate monitoring system 1 Lift the rate monitor and position over machine throat 2 Setin position and secure by tightening four bolts 3 Remove lifting strap 4 Mount the material conveying system receivers on the top of the rate monitor s surge hopper If a mezzanine mounted GH Hopper is being used to supply material to the rate monitor attach the flex hose to the top of the surge hopper 5 Install the weigh hopper onto the load cell bracket Tighten the two supplied thumb screws to the flange on the weigh hopper Note Use extreme care when tightening bolts on top of the load cells so you do not spring the load cells The load cells are extremely delicate and should be treated with care 6 Check to see that the weigh hopper is completely unrestricted The load cell bracket should not to
31. ber Chapter 3 Installation 32 of 61 Alarm Setup This screen allows the operator to configure the alarm settings for the rate monitor To configure the alarms do the following 6 Enter the Setup Menu 7 Once in the Setup menu press Alarm Setup This will take you to the Alarm Setup screen Figure 18 Alarm Setup Screen ALARM SETUP Min System Speeds Man System Speeds Hopper 5X for low level alarm Hopper X for no material alarm Out of Material Alarm Silence De lau Changes weigh hopper weight for no material Change the Alarm alarm Silence Display 8 Press the Done key at the bottom to exit this screen Min Max Speed Limits restrict the usable gravimetric range that the GH will permit in order to continue gravimetric measurement If the system becomes unstable for more than the System unstable alarm time then an alarm will notify the operator The Hopper for low level should always be set below the reload percentage hopper setup page and the Hopper for no material alarm should always be set below the low level 46 Vacuum Bypass Setup Enter in the amount of material that is stored above the reload valve This is only used if you are using the easy change over feature Vacuum Bypass Setup Enter the weight that is held above 000000 the reload gate Be sure to consider the weight in the vacuum hopper Done Bulletin Number Chapter 3 Instal
32. d If the rate monitor is being refilled from a mezzanine mounted GH Hopper the surge hopper lid will have a tube stub on it The surge hopper will be mounted on the frame at the factory The 24V dc solenoid will also be factory wired In some rare cases it may be necessary to remove the surge hopper for shipping purposes Weigh Hopper The weigh hopper is located within the GH M frame The hopper size is set within the controls Default for refilling to occur is 50 of the weigh hopper size The weigh hopper on the rate monitor is used to weigh the material entering the extrusion process Once the weigh hopper goes below 50 of its set weight capacity the solenoid valve on the surge hopper will open allowing material to fall from the surge hopper to the weigh hopper The surge hopper solenoid will close once the weigh hopper reaches its set weight capacity Details for installing and removing the weigh hopper are included in the next section The weigh hopper will need to be installed before operation can begin It is necessary to remove the weigh hopper for shipment so the loadcell is not damaged When the weigh hopper is installed use care not to damage the load cell Position the hopper Note Use care when replacing the weigh hopper since the load cells are delicate weighing instruments and can be easily damaged Do not use force to push in the weigh hopper Note Load cells if damaged will have to be sent back to the manufactur
33. d entered recipe target you must also reset this bit after completion 10 change layflat I1 BIT 8 toggle to load layflat value you must also reset this bit after completion STEADY FLAGS l 2 3 4 system stable O1 BIT 5 extruder rpm stable O1 BIT 6 extruder wm stable O1 BIT 7 hauloff stable O1 BIT 8 DESIRED SHUTDOWN TIME WRITE A 0 TO DISABLE 1 desired shutdown time in minutes I F 12 Bulletin Number Chapter 9 Item 56 of 61 WRITING SETPOINTS EXPLANATION Extruder RPM set points recipe set points and haul off set points can be wrote to while the unit is in stop mode After engaging either RPM mode or Weight mode then the appropriate values will be applied While in RPM mode the target recipe value will be overwrote by what the current actual running value is This ensures that when you transfer to Weight Mode that the line set points do not change This acts as a virtual cruise control for your line Bring the extruder and haul off up to the desired outputs and then place the unit in Weight Mode to maintain the ratio even as the screen pack builds up material over time The Extruder RPM set points and haul off set points can be modified while in RPM mode and the unit will respond immediately The Recipe set point can be modified while in Weight mode Some recipe set points may include the extruder RPM or the haul off speed depending on the recipe mode selection If the recipe mode selection is Ibs
34. ding freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned immediately without any further use or handling Warranty Liabilities THE COMPANY EXPRESSLY DISCLAIMS ANY AND ALL LIABILITY FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES OR EXPENSES THAT RESULT FROM THE USE OF THIS PRODUCT Some states do not allow the exclusion or limitation of special consequential or incidental damages so the above limitation may not apply to you The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty No person agent manufacturer distributor dealer installer or company is authorized to change modify or extend the terms of this warranty in any manner whatsoever The time within which an action must be commenced to enforce any obligation of the Company s arising under this warranty or under any statute or law of the United States or any state thereof is hereby limited to the duration of this warranty Some states do not permit this limitation so the above may not apply to yo
35. e hopper is sized based on the total throughput of the extrusion rate monitoring system Each surge hopper contains a 24V DC solenoid that is used to open and close the internal dump cone The internal urethane dump cone is mechanically opened and closed with a compressed air cylinder The rate monitor s surge hopper does not include any level indication devices as standard equipment Optional surge hopper low level sensors are available The rate monitor controller will alarm if it runs out of material while trying to fill the weigh hopper but low level sensors will alert floor personnel to the problem sooner If an optional low level sensor is purchased it will activate a visual alarm This optional proximity switch can be mounted anywhere the customer desires and is not mounted unless specifically requested The refill system is equipped with a manual key switch to open and close the surge hopper This three position key switch is located on the front of the PLC enclosure Figure 5 Typical Surge Hopper Figure 6 Refill Switch Positions Position Description The rate monitor controller automatically controls surge hopper AUTO functions OPEN Dump cone gate open all the time CLOSE Dump cone closed all the time Bulletin Number Chapter 2 Functional Description 15 of 61 Each surge hopper is supplied with a lid Standard lids contain a cutout to accept a vacuum receiver A blank lid may also be provided if specifie
36. ect planning system packages including drawings equipment labor construction materials and union or non union installations Bulletin Number Chapter 9 Item 61 of 61
37. ee edax mentis 44 Customer Responsibilities AAA 45 Annex B Information m 45 7 2 Addendum Service Supervisor Information ssseeeeee 47 Programmable ee 47 Customer Setup Menu oe i etr Ep be eee eae 52 7 3 Siemens S7 200 Communications Manual 53 7 4 ITEMS IN BLUE ARE READ ONLY ITEMS IN BLACK ARE WRITE ONLY 53 CHAPTER 9 ITEM iioii e see n Ee RUE Rue vn eege PAHS DODANTIONE oc 3k caressed 61 ee EE 61 Sales Deparimehl e od HERREN DR qucd i dad ERN HEUS 61 Contract Departments eire e ak ott rr e nat ite nente 61 vi Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your rate monitor The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the GH hopper We can also provide the assistance of a factory trained technician to
38. er for testing and evaluation Note Make sure no part of the load cell bracket is touching the plastic housing on the load cell This could result in inaccurate weight readings If necessary the plastic on the loadcell can be trimmed back tube stub as close to the center of the hole in the bottom of the frame as possible Operator Control Panel Display The operator control panel includes an 8 foot 2 4 m cable and can be remote mounted not recommended adjacent to the GH Hopper The panel can be unplugged and removed if necessary The cable provides 24VDC power to the display as well as communications to the PLC A programmable logic controller PLC controls the rate monitor operation This design provides excellent performance along with an easily replaceable control panel in the unlikely failure of any computer or electronic part After installation and setup the GH M will begin monitoring the system process once the rate monitor detects an extruder speed The following figures show some typical screens of the GH M rate monitor Bulletin Number Chapter 2 Functional Description 16 of 61 Figure 8 Typical Siemens 87 200 Controller Touch Screen Display EXT RPM Stable EXT WTP Stable Figure 9 Controller Pushbuttons amp Touchscreen Tags Turns power on to the GH Hopper controller Power On Found on the back of the controller Turns power off to the GH Hopper controller Power Off Found on the back of the
39. erage consumption at the feed throat always equals what is coming out at the die However the instantaneous feed throat usage is not equal to the usage at the die This is due to the pressure barrier sections and design of your extruder The goal of the GH system is to accurately control and measure what is coming out the die and not to respond to nuance changes at the feed throat It is not recommended that you reduce this setting unless consulting engineering or service and you fully understand this feature Full Hopper Method This is the most stable of all 3 choices Upon reloading a weight snapshot and time are used to calculate the overall usage since the last reload This is also the least responsive setting WTP RPM Filter When switching between the 3 methods you need to understand the sample time and configure the WTP RPM Filter appropriately A good example of this is that by default the hopper is configured to reload at 5096 keeps material in the vertical section of the hopper sample in Percent of Hopper Method at 20 and uses a filter of 9 If it is desired to switch to the Full Hopper Method then you don t need a filter of 9 A filter of 9 uses 10 points At a sample of 20 you get 2 samples per reload It would therefore take 5 reloads to fill the analyzer upon starting the line After that the measurement will be updated with each and every 20 When switching to the Full Hopper Method you onl
40. g so Pressing the manufacturer s icon when in the Setup Directory Screen menu accesses this menu Figure 67 Typical Operator Setup Screen Touch this icon and enter in the Service Password to access the Engineering Only Directory Bulletin Number Chapter 7 Appendix 47 of 61 Enter the long password 3145348 and press Enter The factory setup section displays the Engineering Only screen The screen similar to that shown below should be displayed and use the keystrokes described herein to change or toggle the parameters HTF Algorithm Options Mechanical Options Go back to Analog Options Setup Directory Select the desired menu to advance to the screens listed below The exit to the Setup screen select Done Figure 69 Typical Advanced Weight Options Screen Advanced Weight Options Time to settle hopper after reload valve has shut sec Hopper Weight 0000 000 Lbs No Flow Timer 0000 No Flow Bits 0000 Done Advanced Weight Options Screen Increase the Time to settle hopper after reload valve has shut if the hopper needs more time to settle after reloading Increase No flow timer and decrease No flow bits to reduce nuisance no flow alarms Set to 0 will disable this alarm Figure 70 Typical WTP Alogorithm Options Hisgorithm Uptions Extruder Pulse Count Method Percent of Hopper for Calculation Number of Pulses for Calculation HHH
41. ical Features and GCombpaonenls c tors gees ege EE gege 14 Mechanical Features eo x Eee ims med du dem 14 Controller POAIURSS ee Eege Eege 14 System Component Description esses sesenta 14 Extruder Inductive Proximity Switch 15 Surge Tei 15 Weigh Hoppet Ree Soke Hones te be a ee la ne EE 16 Operator Control Panel Display 16 2 4 COPUONACOMPONEING ee eege 20 PRONDUS DP SIQV 0 x aieo iet Eege eg 20 Pneumatic Slide Gate below surge bopper 20 Low Level Proximity Sensors ics se iu canted ys ert eto eras esit dbi Ee 21 2 5 Safety EE 21 CHAPTER 3 INSTALLATION eee 22 3 1 Un rating the e len EE 22 3 2 Mechanical lristallatiOrt nete iterat eg sace a tret eos 22 Site Hequiremehts E 22 Mounting Configurations eege e Ee eege 22 Machine Mount teet eter sheds as see bei ENEE geg 23 349 Electrical ConNeCtONS E 23 3 4 Pneumatic Connections 5 odi reed becorka eege 24 COSME ER 25 Mechanical Setia stes o a eoa e te sab P beu teda pnt 25 Weigh Hopper Installation fn eee ete ene peret fede 25 Extruder RPM Connection nennen enne enters en nennen nens 25 Final Connections oet dete eret tete e Edel Petre lene pea etna ee de 26 CORIFOller EE 26 GH Controller Menu Structure acainnean ara AEA EEEE 28 Rate Monitor Calibration nennen enne enne ener a 28 Rate Monitor Calibration reeeetete eet tete es
42. lation 33 of 61 Figure 32 PanelView Configuration Screen Panel View GH Version Main 1 5 PLC GH Version PLC Operating System Series PLC Operating System Firmware Bulletin Number Chapter 3 Installation 34 of 61 3 6 Initial Startup The system will begin monitoring the process rate once an RPM reading from the Extruder is detected Again this RPM must be communicated to the PLC through the supplied inductive proximity switch or through the Profibus DP Slave module The extruder icon on the recipe page will become animated indicating the extruder is running and the measured Extruder RPM will be displayed If the system does not automatically start loading upon starting of the extruders then check this value for trouble shooting At this point the controller will refill the weigh hopper to its set weight capacity The GH M rate monitor will start tracking the extruder as soon as it is started The displayed value may be far from the actual value the first time the system is ran The GH M goes through a learning process with each material This is indicated by a Steady Process indicator on the main recipe page Upon starting the line you should always give the hopper time to analyze the flow and give you a Steady Process before making adjustments based on the displayed throughput The initial learning process will be complete when the Steady Process indicator is displayed on the recipe screen
43. ld not use this section of the manual and or program can be compromised Note Hidden programmable features and hidden menu pages should not be made available to floor operators These pages include the Service Supervisor Information addendum located in this section Unauthorized changes to these factory settings by inexperienced operators may prevent the unit from operating properly and may void part or all of the warranty Caution After all selections are made Keep pressing the Done key until the unit returns to the Recipe menu Note Inexperienced operators or inexperienced plant personnel should not access programmable features Unauthorized changes may prevent the rate monitor from operating properly and may void part or all of the warranty Note Call the Service Department for assistance or for further explanation of these or any other programmable features which may or may not be shown in this manual Note Information included in this manual is subject to change without notice Passwords e User Password 5413 e Maintenance Password 3145348 Caution Maintenance password should only be supplied to qualified personnel The program can be compromised Programmable Settings The rate monitor software program has been designed to allow some customizing to achieve certain desired operating parameters The following is a listing of the selections that are field programmable followed by the procedure for doin
44. le each vacuum conveyer for each individual hopper If the GH runs out of material prior to it s expecting time then it is up to the operator to reset the desired shutdown time in minutes to allow it to convey and continue loading An example would be an hour before the operator wants to shutdown they would enter in the shutdown time of 60 minutes into a touch screen cell on your master controller Your controller would then write a value of 60 to the desired shutdown time in minutes and would write to us the process rate The blender would use this process rate and other items to determine when it should disable the loaders Based on that data the blender decides to disable the loading for GH five minutes before the countdown time of the original 60 minutes has passed However at 2 minutes prior to the original countdown time hopper 1 runs out of material and alarms Hop Out of Material The operator at that time can either shutdown the line 2 minutes early or can change the value of 60 to 0 and the system will reload the GH again At that time the operator can enter a value of 2 minutes and the system will disable the loaders for the last 2 minutes of the run This feature will require tuning and practice on the part of the operator to achieve the correct shutdown sequence but if done properly will save the operator time and work in having to empty out full supply hoppers Bulletin Number Chapter 9 Item 57 of 61 PLC WORD ADDRE
45. llowed max System rate is above allowed maximum setting extruder overspeed Extruder is out of allowed linear range extruder underspeed Extruder is out of allowed linear range hauloff overspeed Hauloff is out of allowed linear range ONLY ON FULL CONTROL hauloff underspeed Hauloff is out of allowed linear range ONLY ON FULL CONTROL feeder overspeed GHF only GHF Feeder is running too fast feeder underspeed GHF only GHF Feeder is running too slow plc battery low replace battery with power on as soon as possible Figure 48 Typical Manual Control Operator Screen MANUAL CONTROL CAUTION System Will stop if manual reload is turned on Hop Ht Hee Lbs The dump valve opens as soon as you touch the Reload Off button The button then changes to show Reload On Note The system will stop if you attempt to turn the manual reload on This could be devastating if you are running the extruder Print Inventory The print inventory menu item is used to produce on demand inventory printouts Before selecting this item be sure that the printer is properly connected and ready This function will generate an inventory Bulletin Number Chapter 4 Operation 38 of 61 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule The mechanical design of the GH Hopper is very simple and very little maintenance is required The only moving parts are the metering gates weigh hopper dump valve and mixer agitator The
46. nds hour with Siemens 57 200 Controls Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Rate monitoring systems are as varied as the applications they service All gravimetric rate monitors are sized to meet the specific requirements stated by the Customer at the time of purchase 2 2 General Description Rate monitors are designed to measure the extrusion rate of plastic pellets and regrind Standard equipment is not designed to measure powder or any other materials Optional equipment may be purchased to measure the extrusion rate of powders Accessories The manufacturer offers a variety of standard options for GH M rate monitors including knife gates low level proximity switches Profibus DP Slave communication modules and hoppers specifically designed to measure the extrusion rate of powders All accessories are designed and manufactured to ensure proper results for your application Customer Service The intent of this manual is to familiarize the operator and maintenance personnel with these rate monitors and help your organization get the maximum service from your equipment If you have any questions regarding installation service repair custom equipment or applications please do not hesitate to contact us for the information required Prices for additional equipment accessories or repair parts will be furnished
47. nts more than one pulse per revolution this value may be changed on the Mechanical Options page also Simply input the number of pulses per revolution in the Extruder PPR field Bulletin Number Chapter 7 Appendix 50 of 61 The hauloff encoder setting is not functional for the rate monitor controller The GHF feeder max RPM setting is not functional for the rate monitor controller Figure 72 Typical Analog Options Analog options screen H truder HHHH Done This screen is not used with the GH M Rate Monitor Adjust appropriately for GH Full Control units Figure 73 Typical Diagnostics Screen EEN HHH H JA H HHHH A HEHH A JA H FE HHHH 8 HHHH H FREE 8 RE adit i Reset Hish Lows Go back to A Target Extruder RPM 4 Engineering Only Directory HUMBER OF WTP E ees MEASUREMENTS EXT RPM Stable mem EXT WIP Stable B Hauloff Stable Diagnostics Screen Use this screen for trouble shooting and making tuning adjustments Typically make an adjustment reset high lows and then weight for some time to observe this page Bulletin Number Chapter 7 Appendix 51 of 61 Customer Setup Menu Units This screen allows the user to change the GH Hopper s unit of measurement The entire GH Hopper can be configured in either Kgs or Lbs while the Target vs Actual data can be configured for either regardless of the GH Hopper s units Bulletin Number Chapter 7
48. or and surrounding area DAILY and inspect the machine for loose missing or broken parts Shut off power to the GH Hopper when it is not in use Turn the switch to the OFF position or unplug it from the power source Chapter 1 Safety 11 of 61 Maintenance Responsibility Proper maintenance is essential to safety If you are a maintenance worker you must make safety a priority to effectively repair and maintain equipment Before removing adjusting or replacing parts on a machine remember to turn off all electric supplies and all accessory equipment at the machine and disconnect and lockout electrical power Attach warning tags to the disconnect switch When you need to perform maintenance or repair work on a rate monitor above floor level use a solid platform or a hydraulic elevator If there is a permanently installed catwalk around your rate monitor use it The work platform should have secure footing and a place for tools and parts DO NOT climb on unit machines or work from ladders If you need to repair a large component use appropriate handling equipment Before you use handling equipment portable A frames electric boom trucks fork trucks overhead cranes be sure the load does not exceed the capacity of the handling equipment or cause it to become unstable Carefully test the condition of lifting cables chains ropes slings and hooks before using them to lift a load Be sure that all non current carrying part
49. ory you must also reset this bit after completion 2 hopper_inventory O F 3 3 hauloff accumalated length O F 5 EXTRUDER SETPOINT INFO 1 entered extruder rpm target I F 2 write desired rpm here 2 extruder rpm target O F 7 3 extruder rpm instant I F 4 write rpm value here if you are not using the extruder prox signal for the calculation 4 actual extruder rpm instant O F 9 HAULOFF SETPOINT INFO 1 entered hauloff speed target I F 6 write desired line speed here 2 hauloff speed target O F 11 TARGET GENERATED BY SYSTEM Bulletin Number Chapter 9 Item 55 of 61 3 current_measured_hauloff_speed O F 13 ACTUAL MEASURED RECIPE SETPOINT INFO pa 9 e E ce peus entered recipe target JOE 8 write desired recipe entry here such as Ibs hr Ibs ft lbs ft recipe_running_target O F 15 running target based on hopper mode recipe actual value O F 17 compare this to target for accuracy ext_wtp_target O F 19 Ibs hr or kgs hr depending if the system is in imperial or metric ext_wtp_average O F 21 Ibs hr or kgs hr depending if the system is in imperial or metric layflat I F 10 change entered extruder rpm target I1 BIT 5 toggle to load entered extruder rpm target you must also reset this bit after completion change entered hauloff speed I1 BIT 6 toggle to load entered hauloff speed you must also reset this bit after completion change entered recipe target I1 BIT 7 toggle to loa
50. ou need to write the speed through from a Profibus DP Master as mentioned at the end of this manual Pneumatic Slide Gate below surge hopper The surge hopper can be equipped with a pneumatic slide gate in lieu of the air cylinder and urethane dump cone The knife gate is opened and closed by the PLC A 24 VDC solenoid is used to open and close the knife gate umber Chapter 2 Functional Description 20 of 61 WARNING Slide gates create a pinch point hazard Low Level Proximity Sensors Detects material supply problems before rate monitor hoppers are empty A 24VDC capacitive proximity switch is utilized for this option The proximity switch is wired directly into the PLC enclosure If there is a material supply problem a visual alarm is activated 2 5 Safety Features This section includes information on safety devices and procedures that are inherent to the rate monitor system This manual is not intended to supersede or alter safety standards established by the user of this equipment Instead the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment Bulletin Number Chapter 2 Functional Description 21 of 61 Chapter 3 Installation 3 1 o 3 2 Uncrating the Equipment Rate monitors are shipped mounted on a skid enclosed in a plastic wrapper and contained in a crate 1 Remove crate from around the rate monitor 2 Secure strap of proper lifting cap
51. p Page gt Touch the ACS icon and enter in the user password Chapter 3 Installation Recipe Format gt System Rate amp Line Speed gt Weigh Per Length Mode gt Weight Per Area Mode Hopper Setup gt Hopper size gt Reload Percentage Extruder Setup gt Maximum Extruder RPM gt GHF Extruder Max Throughput Hauloff Setup Hauloff enable disable Read Do Not read speed from COEX Master Hauloff Max Speed Calibrate Encoder Calibration gt Scale Calibration gt Direct Scale Readout gt Weight RPM Calibration Panel View Config gt Panel view GH version PLC GH version Units gt Lbs vs Kgs Password gt New Password gt Verify Password Alarm Log gt View print and clear the alarm log Alarm Setup gt Min System Speed gt Max System Speed gt System Unstable Alarm Time gt Maximum allowed reload time gt Hopper for low level alarm gt Hopper for no material alarm gt Out of material alarm silence delay Vacuum Bypass Setup gt Configure how many much material is stored in the supply hopper 28 of 61 Rate Monitor Calibration The load cell on a rate monitor is FACTORY CALIBRATED Since the load cell can be subject to shock loading during shipping moving etc we recommend that they be recalibrated The heart of the rate monitor system is the load cell and the supplied calibration weight Since the load cell is weighing the amount of ma
52. r s target LBS HR calculation Figure 17 Hopper Setup Maximum Extruder RPM dHHHBHE ONLY FOR H GHE FEEDER GHF Extruder Mas Throughput Hauloff Setup and Encoder Calibration Page GH Full Control ONLY Use this page to enable the hauloff option of the GH Full Control Unit The unit should be set to Do not read speed from COEX Master if a COEX AB does not exist If it does then this setting is automatically setup by the COEX Master The Hauloff max speed must be entered if you are not using an encoder see mechanical options to turn this feature on off If you are using an encoder then you must calibrate the encoder by running the line at a known speed hand measuring the line speed with a tachometer entering the speed into the ft min box and then clicking the click here box You can also manually modify this calibration by adjusting the Distance per revolution of encoder Figure 17 Hopper Setup and Encoder Calibration Page HRULOFF ENCODER CALIBRATION Distance Per Revolution of Encoder iHHHBHE ft Measured Hauloff Speed ft min Hauloff Enabled Do not read speed from COEX Master Hauloff Max Speed ft min Target Hauloff Speed dHHHE Measured Hauloff Speed dii 8 ft min To automatically calculate Distance Per Revolution enter actual measured speed below then click here Calibrate Encoder ft min RPM or Weight Mode only Bulletin Num
53. rective Maintenance Electrical This section is designed to give the operator an overview of the electrical system that controls the GH Hopper system Since the hopper s control panel is a self contained pluggable item seldom will a maintenance person be required to enter the control panel For purposes of understanding the system it is advisable that the maintenance personnel be familiar with not only the internal workings of the control panel but also with the input and output signals to the GH Hopper This section includes the following e Internal components of the control panel e Input signal to the control panel Output signals from the control panel Internal Components of the Control Panel Note See Installation Packet supplied with unit for complete electrical schematics This section describes the internal components of the GH Hopper system control panel It is not the intent of this section to completely familiarize the reader with the details on industrial control panel construction or standards but simply to familiarize the reader with the major components inside the control panel The customer must supply 120 1 50 or 60 or 220 1 50 or 60 via wires L1 amp L2 N Please insure that the earth ground connection is properly connected to an established earth ground e Power on is indicated by a lighted on off switch e Reload switch controls the vertical reload gate above the hopper e Safety Active light displays s
54. ruder WTP average MSW extruder WTP average LSW Hopper percent weight 0 1150 Total weight minus tare material weight MSW Total weight minus tare material weight LSW not used not used Chapter 9 Item 59 of 61 V1418 28 not used V1420 29 not used V1422 30 not used V1424 31 V1426 V1427 0 32 INT bit O alarm active V1427 1 bit1 heart beat alternates every D second Bulletin Number Chapter 9 Item 60 of 61 Technical Assistance Parts Department Call Spare Parts Express toll free 8am 8pm EST 800 423 31839 or Phone 847 273 7700 Fax 847 273 7812 OEM quality replacement and spare parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call toll free 800 423 3183 8am 8pm EST Emergency service available 24 hours a day We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 847 273 7700 Monday through Friday 8am 5pm CST Our products are sold by a worldwide network of independent sales representatives Contact our sales department for the name of the sales representative nearest you Contract Department Call 847 273 7700 Monday through Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services proj
55. s are correctly connected to earth ground with an electrical conductor that complies with current codes Install in accordance with national and local codes When you have completed the repair or maintenance procedure check your work and remove your tools rigging and handling equipment Do not restore power to the rate monitor until all persons are clear of the area DO NOT start and run the unit until you are sure all parts are functioning correctly BEFORE you turn the rate monitor over to the operator for production verify all enclosure panels guards and safety devices are in place and functioning properly Reporting a Safety Defect If you believe that your equipment has a defect that could cause injury you should immediately discontinue its use and inform the manufacturer The principle factors that can result in injury are failure to follow proper operating procedures i e lockout tagout or failure to maintain a clean and safe working environment Bulletin Number Chapter 1 Safety 12 of 61 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for rate monitors of various extrusion rates and specifications See below for a list of available models e GH M 10 Rate Monitor 50 600 pounds hour with Siemens 87 200 Controls e GH M 20 Rate Monitor 300 1 500 pounds hour with Siemens S7 200 Controls e GH M 40 Rate Monitor 1 000 2 500pou
56. s available to the operator These displays are selected simply by pressing the NEXT key when the unit is running The default display shown when the rate monitor is in run mode is the Recipe Screen Figure 35 Typical Inventory Display Operator Screen INVENTORY ACS Total Lbs HHHHHHHHHE Group Total Feet iHHHHHHHHHE Clear Manual Inventory Control Bulletin Number Chapter 4 Operation 37 of 61 Alarm Flags An alarm message will be shown if any alarm condition occurs A message will pop up on the screen until the alarm condition is resolved The operator can press OK on this pop up to hide the screen temporarily but if the alarm condition is still unresolved then the message will reappear after a short delay During an alarm condition a visual alarm will be activated The following is a list of all alarm names and descriptions Alarms with Descriptions Hopper low level alarm Hopper is about out of material Hopper out of material Hopper is out of material Inventory cleared Operator has cleared the inventory only logged Extruder no rpm detected alarm ONLY ON GH FULL CONTROL Extruder no flow detected alarm ONLY ON GH FULL CONTROL Hauloff drive failure alarm ONLY ON GH FULL CONTROL Loadcell over max alarm check loadcell circuit Reload too long alarm First indication that you are about to run out of material System not stable alarm System has been unstable for too long hopper flow over a
57. s injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Bulletin Number Chapter 1 Safety 7 of 61 Figure 1 Safety Tags and Warning Labels Tag Description Description Read Operation amp Pinch Point Slide Gate Installation Manual e Shear Point Rotating Earth Ground Mixer High Voltage Inside Protected Earth Ground Enclosure A Shear Hazard Rotating Lifting Point v Auger Bulletin Number Chapter 1 Safety 8 of 61 1 2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices EN m Read and follow these operation and installation instructions when installing operating and maintaining this equipment If these instructions become damaged or unreadable additional copies are available from the manufacturer Follow all SAFETY CODE
58. steps above to calibrate the rate monitor If your rate monitor is frequently out of calibration verify the operator is being cautious removing the weigh hopper Press Done until you have reached the Recipe screen Anything in the Diagnostics Menu that is not covered here is in the Detailed Controller Setup Section WTP RPM Calibration Page This page is used to monitor the Ibs hr per RPM analyzer and is used as a tool for tuning the WTP Algorithm Options mentioned later in this book HHHHHH ot 0 HHHH LALLA ooooooooo WONTON a bd at HHHH HTPRPEN Dif Hopper Size Setup The weigh hopper size is factory set In may be necessary however to change this value due to varying bulk densities of material L Cho nau i9 Bulletin Number Enter the Setup Menu Select Hopper Setup Enter the required size for the weigh hopper should be close to full Set the refill percentage to 50 Press done to return the setup menu Figure 17 Hopper Setup Hopper size 34HHHH Lbs Reload Percentage 5 Chapter 3 Installation 3 of 61 Extruder Setup Use this page to setup the Maximum Extruder RPM This is critical for GH Monitor units and GHF feeder units This value is automatically calculated with GH Full Control units Also for GHF Feeder units you will need to program in the maximum LBS HR of the extruder for the feede
59. tatus of safety interlock circuit Audible alarm horn alerts operator to GH Hopper fault Bulletin Number Chapter 5 Maintenance 40 of 61 Input Signals to Programmable Controller The rate monitor system has two main input signals that it uses from the extrusion process the weigh hopper load cell and the extruder speed reference This of course does not include the operator touch screen input The extruder speed reference is generated from the supplied inductive proximity switch or is wrote to the PLC through the Profibus DP Slave module Load cells require 12 volts DC to operate This is known as the load cell s excitation voltage Output Signals from Programmable Controller The rate monitoring system uses several output control signals to control the process All of these are very similar in nature The surge hopper refill solenoid is controlled by a PLC output Bulletin Number Chapter 5 Maintenance 41 of 61 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the
60. te tere teet oes retia eet sene Een 29 WTP RPM Calibration Page ceria teenete neee ident eie ete ENEE 31 This page is used to monitor the Ibs hr per RPM analyzer and is used as a tool for tuning the WTP Algorithm Options mentioned later in this book 31 Hopper 5126 Setup Lei Redit tot eR ec eere reete tte 31 bxtruder Setup EE 32 Hauloff Setup and Encoder Calibration Page GH Full Control ONLY 32 EBEN E Du 33 Macuum Bypass Setup iit ttu ite certe e tr ipt eH i oec 33 3 6 initial SIaPDUD EE 35 CHAPTER 4 OPERATIQN ee oca dvape tun E erras 36 e i En Gi DEE 36 General OD ERATION ies neiaie a ioco a Roc adeo tb bet eas le eich 36 Quick Star POCO CUO x EE 36 EE iiis RU RO ERIGI UT Ir E dE 36 4 2 Operation el 36 Operator DISDIAVS isase ni p e oret ER dot sabre ber EE ab 36 72777 i zio e 38 CHAPTER 5 MAINTENANCE BER BRR RRR RRR RR RR RRR REPRE RRR RRR REPRE RRR ee eee 39 5 1 Preventative Maintenance Gchechule AAR 39 5 2 Preventative Maintenance TE 40 5 3 eeh 40 CHAPTER 6 TROUBLESHOOTING BER BRR RRR RRR RR RR RRR RRR RRR eee 42 eh MM ee elle EE 42 CHAPTER Tq APPENDIX esas pe cada rl Usa eue rade ee 44 7 1 Warranty and Spare Paris uiis ce pert rh ec odo i M Fita RESP RAI ERR E Lr EHE 44 Warranty Specifications Eege ee 44 Warranty RHesiricliohs 1E Pn ie e RR EIN Meta vteludte Pate ne ed uia qt 44 Warranty Liabilities seo Ente t
61. terial entering the process proper calibration of the load cell is essential for the correct and accurate operation of the rate monitor This calibration must be performed upon initial installation and startup The calibration should also be checked once a month with a calibration weight and if necessary recalibrated to ensure that it has not been damaged in the normal routine of removing and replacing the weigh hopper for cleaning The calibration of the load cell is accomplished by using two reference points on the output of the load cell scale The first of these points is known as the Tare Weight This is the weight of the empty weigh hopper assembly on the load cell This is also known as the zero weight point starting point of the scale This zero or starting point must be initialized with an empty weigh hopper There must be no binding or leverage put on the load cell The second weight point used in the load cell calibration procedure is a known amount of weight for the weigh hopper A calibration weight is provided with all rate monitors The calibration weight is stamped with its actual weight on top If this is not available any object with a known weight accurate to the nearest 1 1000th of a pound in the 2 10 Ib range proportional to your size rate monitor will suffice The weight should be as close as possible to the weigh hopper s capacity The weight will be in pounds unless the rate monitor is provided for metric operation
62. the equipment do not exceed 60 psi 4 14 bar air Caution Always disconnect the compressed air supply when working on any part of the rate monitor Bulletin Number Chapter 3 Installation 24 of 61 3 5 Initial Set up This section will discuss the mechanical setup and control system setup of the rate monitor system After reading this section you should be familiar with the mechanical setup and the electronic control setup of the rate monitor Mechanical Set up Weigh Hopper Installation It is necessary to install the weigh hopper Remove the weigh hopper from the shipping box and install it onto the load cell bracket Two provided thumbscrews are used to secure the weigh hopper to the load cell bracket Figure 12 Picture of Weigh Hopper Note THE WEIGH HOPPER ASSEMBLY MUST HANG FREELY AND BE FREE FROM FRICTION WITH NO MECHANICAL OBSTRUCTIONS OTHER THAN THE LOAD CELL ITSELF It is very important the tube stub of the weigh hopper does not touch the supplied dust ring It is also important the flange of the weigh hopper be completely flush with the load cell bracket Extruder RPM connection The supplied inductive proximity switch must be mounted to accurately read the Extruder s RPM The extruder s speed may be reported to the controller via communications see communications section at the end of this manual The proximity switch must be mounted securely and read the actual RPM of the extruder Supplementary documenta
63. tion on this proximity switch is provided from its manufacturer To wire the supplied inductive proximity switch the PLC enclosure please refer to the supplied wiring schematics Bulletin Number Chapter 3 Installation 25 of 61 If you are writing the extruder speed through Profibus then the proper setting has to be changed to measure the extruder s RPM with communications For details on changing the settings for measuring the extruder s RPM please refer to the Addendum 7 4 Final Connections Connect the rate monitor to the appropriate power source Connect the compressed air piping ensuring that a 5 micron air filter is installed along with the proper water trap Verify that 60 psi of clean dry compressed air is supplied to the GH Hopper After powering up the rate monitor the following screen will be shown Figure 13 Display Startup Screen Touch here to skip quickly to the Recipe Screen Next Screen in sequence version Main 1 5 000 Extrusion Monitoring a gt PLC Version Copyright HHHH 8 Ze Note It may take 45 50 seconds for the screen to appear This screen displays the software version of both the PLC and the PanelView The Controller will stay on this screen for about 10 seconds or you can touch the ACS icon to quickly skip to the Recipe Screen Next Screen in sequence The software versions are also available on the Panel View Configuration Screen Figure 14 Display Main Recipe Screen
64. u This warranty gives you specific legal rights and you may also have other rights which vary from state to state For transactions involving the potential applicability of international law or that of a foreign country this warranty policy and the procedures hereunder shall be governed by applicable federal and state law but not by the United Nations Convention on Contracts for the Sale of Goods Bulletin Number Chapter 7 Appendix 44 of 61 Customer Responsibilities Any sales use or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser Annex B Information The following design information is provided for your reference 1 2 Qo Sd V UV aea s 11 12 13 14 15 16 17 Cable support may be required for power cord depending on final installation 19 20 Two hand control is not required or provided 22 23 21 24 25 26 Bulletin Number No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature 40 degrees Celsius Maximum 104 degrees Fahrenheit Humidity range 50 relative humidity Altitude Sea level Environment Clean dust free and non explosive Radiation None Vibration Minimal i e machine mounting Special installation requirements Clean dry compressed air 1 cfm 60 psi 1 7 m hr 4 14 bar Allowable voltage fluctuation 10 Allowable frequency fluctuation
65. uch any part of the plastic housing on the load cell The tube stub on the bottom of the weigh hopper should not touch any part of the cast spool If either of these conditions are not met inaccurate weight readings may result Site Requirements This section describes site requirements in detail These requirements are broken down into mechanical mounting electrical connections and pneumatic connections Mounting Configurations The rate monitoring system must be machine mounted Bulletin Number Chapter 3 Installation 22 of 61 Machine Mount The GH M rate monitor must be machine mounted There are a few items to review before placement and mounting of the rate monitor system begins First verify the machine flange dimensions match the cast spool mounting flange Verify that the machine throat is physically capable of supporting the rate monitoring system with a full load of material and vacuum loading equipment installed Note While in operation the rate monitoring system applies horizontal and vertical pressures to the mounting flange If there is a question as to the mechanical stability of a mounting flange contact the manufacturer s engineering department Verify all clearances on the top and beside the processing machine This is to insure that all motors hoppers control panels etc have adequate room for proper operation and servicing Refer to the assembly drawing with the unit for actual height and width dimensions
66. up unless this value is setup By default this is disabled and must be configured by a knowledgeable service person After running for some time you can go to the WTP RPM Calibration page and observe the average WTP RPM factor You can then set this value above that by 200 300 to eliminate the error caused by draining the hopper while running Figure 71 Typical Mechanical Options Screen Techanical Options hould be facto anlita lon GH Hopper Mode Le S Ty nable GHF Feeder set to GH Hau RPM HEH H Mrite Ext RPM through COM F13 1 Go back to Removeable Hopper Engineering Only Update Time fHHHHHE 5 Directory Use Hauloff Encoder 18888 PPR Mechanical Options Screen Hopper Mode Used to change the pulses per revolution of the extruder Extruder PPR For a GH M rate monitor the GH Hopper Mode should always be enabled This option should be factory set for a rate monitor The option exists because this software is used for other products The mechanical options screen also allows the user to set the method of obtaining the extruder s RPM This setting should also be factory set If writing the extruder RPM through Profibus then the unit should be set to Write Ext RPM through COM F13 1 If the extruder s RPM is being measured with the supplied proximity switch the unit should be set to Measure Ext RPM with Prox If the mechanical device to measure the extruder s speed prese
67. vise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have M GH M Rate Monitor Frame Display Enclosure w connecting cable cable in PLC enclosure on frame Calibration Weight Weigh Hopper May be mounted on the frame Bill of lading Packing list Operating and Installation packet H HR RR Electrical schematic and panel layout drawings M Component instruction manuals if applicable Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the parts and service department immediately at 847 273 7700 Have the order number and item number available Hold the items until you receive shipping instructions iii Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material the manufacturer must give authorization A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 1596 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number
68. y need a filter of 4 to achieve the same time frame of samples but the response will be much dampened to any oscillation or error in measurement If using the Extruder Pulse Count Method then you must do the math to determine what sample time frame you need Steady WTP RPM Window Bulletin Number Chapter 7 Appendix 49 of 61 No matter which method you chose the analyzer compares the series of measurements to the Steady WTP RPM Window percent to determine if the measurements are stable If this is set too small the system might never give you a Steady Process indication If set too big then the system could respond to nuance changes in the loadcell and cause an erratic response in your control system When set properly the weigh hopper can be hit with a hammer not recommended and it will not cause any error in the displayed measurement Another more common procedure would be if an operator intermittently adds a processing agent to the extruder by dumping it directly into the weigh hopper This will not cause any error due to the measurement algorithm that was previously mentioned Max Allowed WTP RPM If a Ibs hr per RPM value is every calculated above this setting then the GH will ignore the sample This is to prevent an operator from draining a hopper while running and causing an erroneous but consistent measurement The flow through an open drain tube is very consistent and would cause the extruder to respond by speeding

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